CP6015n
CP6015dn
CP6015de
CP6015x CP6015xh
HP Color LaserJet CP6015 Series Printers
Service Manual
HP Color LaserJet CP6015 Series Printers
Service Manual
Copyright and License
© 2008 Copyright Hewlett-Packard
Development Company, L.P.
Reproduction, adaptation, or translation
without prior written permission is prohibited,
except as allowed under the copyright laws.
The information contained herein is subject
to change without notice.
The only warranties for HP products and
services are set forth in the express warranty
statements accompanying such products
and services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
Part number: Q3931-90938
Edition 1, 04/2008
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Table of contents
1 Product basics
Quick access to product information .................................................................................................... 2
Product comparison ............................................................................................................................. 3
Product features ................................................................................................................................... 4
Product walkaround .............................................................................................................................. 7
Front view ............................................................................................................................ 7
HP Color LaserJet CP6015n, HP Color LaserJet CP6015dn, and HP Color
LaserJet CP6015de ............................................................................................ 7
HP Color LaserJet CP6015x ............................................................................... 8
HP Color LaserJet CP6015xh ............................................................................. 8
Back view ............................................................................................................................. 9
Interface ports .................................................................................................................... 10
Serial number and model number location ........................................................................ 10
Supported operating systems ............................................................................................................. 11
2 Control panel
Use the control panel ......................................................................................................................... 14
Control-panel layout ........................................................................................................... 14
Interpreting control panel indicator lights ........................................................................... 15
Control panel menus .......................................................................................................................... 16
Getting started basics ........................................................................................................ 16
Menu hierarchy ................................................................................................................................... 17
Open the menus ................................................................................................................ 17
Show Me How menu .......................................................................................................................... 18
Retrieve job menu .............................................................................................................................. 19
Information menu ............................................................................................................................... 20
Paper handling menu ......................................................................................................................... 21
Configure device menu ...................................................................................................................... 22
Printing menu ..................................................................................................................... 22
PCL sub-menu .................................................................................................. 22
Print Quality menu ............................................................................................................. 24
System setup menu ........................................................................................................... 29
Output Setup menu ............................................................................................................ 35
I/O menu ............................................................................................................................ 38
ENWW iii
Resets menu ...................................................................................................................... 43
Diagnostics menu ............................................................................................................................... 45
Service menu ..................................................................................................................................... 49
3 Paper and print media
Supported paper and print media sizes .............................................................................................. 52
Supported paper types ....................................................................................................................... 56
Special paper or print media guidelines ............................................................................................. 58
Load paper and print media ............................................................................................................... 59
Load Tray 1 ........................................................................................................................ 59
Print envelopes ................................................................................................. 60
Load banner paper into Tray 1 .......................................................................... 60
Load Trays 2, 3, 4, or 5 ...................................................................................................... 60
Load standard-sized paper into Trays 2, 3, 4, or 5 ........................................... 60
Load undetectable standard-sized paper into Trays 2, 3, 4, and 5 ................... 62
Load custom-size paper into Tray 2, 3, 4, or 5 .................................................. 63
Load large-size paper into Tray 3, 4, or 5 ......................................................... 64
Configure trays ................................................................................................................................... 66
Configure a tray when loading paper ................................................................................. 66
Configure a tray to match print job settings ....................................................................... 66
Configure a tray by using the Paper Handling menu ......................................................... 67
Automatic media type sensing (auto sense mode) ............................................................ 67
Auto-sense settings ........................................................................................... 67
Choose an output location .................................................................................................................. 69
Standard output bin ........................................................................................................... 69
Optional output accessories .............................................................................................. 69
3-bin stapler/stacker features ............................................................................ 69
Booklet maker finisher features ......................................................................... 69
Accessory walkaround ...................................................................................... 70
Configure the accessory operation mode .......................................................................... 71
Select the operating mode at the control panel ................................................. 71
Select the operating mode in the printer driver (Windows) ............................... 72
Select the operating mode in the printer driver (Mac OS X) ............................. 72
4 Manage and maintain the product
Information pages ............................................................................................................................... 74
HP Easy Printer Care ......................................................................................................................... 75
Open the HP Easy Printer Care software .......................................................................... 75
HP Easy Printer Care software sections ............................................................................ 75
Embedded Web server ....................................................................................................................... 78
Open the embedded Web server by using a network connection ..................................... 78
Embedded Web server sections ........................................................................................ 79
Use HP Web Jetadmin software ........................................................................................................ 81
iv ENWW
Security features ................................................................................................................................ 82
Secure the embedded Web server .................................................................................... 82
Secure Disk Erase ............................................................................................................. 82
Data affected ..................................................................................................... 82
Additional Information ....................................................................................... 83
Job storage ....................................................................................................... 83
Lock the control-panel menus ............................................................................................ 83
Manage supplies ................................................................................................................................ 84
Print-cartridge storage ....................................................................................................... 84
HP policy on non-HP print cartridges ................................................................................. 84
HP fraud hotline and Web site ........................................................................................... 84
Replace supplies ................................................................................................................................ 85
Locate supplies .................................................................................................................. 85
Supply replacement guidelines .......................................................................................... 85
Approximate replacement intervals for supplies ................................................................ 86
Change print cartridges ..................................................................................................... 86
Change image drums ........................................................................................................ 88
Install memory ................................................................................................................... 91
Install DDR memory DIMMs .............................................................................. 91
Enable memory for Windows ............................................................................ 95
Install an HP Jetdirect or EIO print server card or EIO hard disk ...................... 96
Replace the staple cartridge .............................................................................................. 98
Replace saddle stitch staple cartridges in the booklet maker .......................................... 100
Clean the product ............................................................................................................................. 103
Clean spilled toner ........................................................................................................... 103
Clean the product exterior ............................................................................................... 103
Clean the product interior ................................................................................................ 103
Clean the 3X500 sheet input tray .................................................................................... 105
Clean the IPTU ................................................................................................................ 106
Upgrade the firmware ....................................................................................................................... 107
Determine the current firmware version ........................................................................... 107
Download new firmware from the HP Web site ............................................................... 107
Transfer the new firmware to the product ........................................................................ 107
Use FTP to upload the firmware through a browser ....................................... 107
Use FTP to upgrade the firmware on a network connection using Microsoft
Windows .......................................................................................................... 108
Use HP Web Jetadmin to upgrade the firmware ............................................. 108
Use MS-DOS commands to upgrade the firmware for USB connections ....... 109
Upgrade the HP Jetdirect firmware .................................................................................. 109
Set the real-time clock ...................................................................................................................... 111
Set the real-time clock ..................................................................................................... 111
5 Theory of operation
Basic operation ................................................................................................................................. 114
ENWW v
Sequence of operation ..................................................................................................... 114
Formatter system ............................................................................................................................. 116
Sleep mode ...................................................................................................................... 116
Resolution ....................................................................................................................... 117
Input/output ...................................................................................................................... 117
CPU ................................................................................................................................. 117
Memory ............................................................................................................................ 117
Hard disk ......................................................................................................... 117
Random-access memory ................................................................................ 117
DIMM slot ........................................................................................................ 118
Firmware ......................................................................................................... 118
Nonvolatile memory ........................................................................................ 118
PJL overview ................................................................................................................... 118
PML ................................................................................................................................. 118
Control panel ................................................................................................................... 118
Engine-control system ...................................................................................................................... 119
DC controller .................................................................................................................... 120
Solenoids ........................................................................................................ 120
Switches .......................................................................................................... 121
Sensors ........................................................................................................... 122
Motors and fans .............................................................................................. 123
Fuser control .................................................................................................................... 125
Fuser temperature-control circuit .................................................................... 127
Fuser over-temperature protection .................................................................. 128
Fuser-failure detection .................................................................................... 129
Fuser identification .......................................................................................... 129
Fuser-life detection .......................................................................................... 130
Relay-failure detection ..................................................................................................... 130
Low-voltage power supply ............................................................................................... 130
Overcurrent/overvoltage protection ................................................................. 131
Safety .............................................................................................................. 131
Voltage detection ............................................................................................ 131
Sleep (powersave) mode ................................................................................ 131
High-voltage power supply .............................................................................................. 131
Laser/scanner system ...................................................................................................................... 134
Image-formation system ................................................................................................................... 136
Image-formation process ................................................................................................. 137
Step 1: Pre-exposure ...................................................................................... 138
Step 2: Primary charging ................................................................................. 138
Step 3: Laser-beam exposure ......................................................................... 139
Step 4: Development ....................................................................................... 139
Step 5: Primary transfer .................................................................................. 140
Step 6: Secondary transfer ............................................................................. 140
Step 7: Separation .......................................................................................... 141
vi ENWW
Step 8: Fusing ................................................................................................. 141
Step 9: ITB cleaning ........................................................................................ 142
Step 10: Drum cleaning ................................................................................... 142
Print cartridge .................................................................................................................. 143
Imaging drum ................................................................................................................... 144
Developing roller engagement and disengagement ........................................ 146
Intermediate transfer belt (ITB) unit ................................................................................. 147
Primary-transfer-roller engagement and disengagement ................................ 148
ITB unit detection ............................................................................................ 149
Secondary-transfer-roller unit .......................................................................................... 151
Calibration ........................................................................................................................ 151
Color-misregistration contol ............................................................................ 152
Image-stabilization control .............................................................................. 153
Color-sensor control (duplex models only) ...................................................................... 153
Gray-axis correction ........................................................................................ 155
Pickup, feed, and delivery system .................................................................................................... 156
Pickup-and-feed unit ........................................................................................................ 159
Cassette pickup ............................................................................................... 161
Cassette paper-size and cassette-presence detection ................... 161
Cassette lift operation ..................................................................... 163
Cassette paper-level and paper-presence detection ...................... 164
Multifeed prevention ....................................................................... 165
Multipurpose tray pickup ................................................................................. 166
Multipurpose tray last-paper detection ........................................... 167
Paper feed ....................................................................................................... 168
Skew-feed prevention ..................................................................... 169
Paper-type detection ...................................................................... 170
Feed-speed control ......................................................................... 171
Fusing and delivery unit ................................................................................................... 173
Loop control .................................................................................................... 173
Pressure-roller pressurization control ............................................................. 174
Duplexing unit .................................................................................................................. 175
Duplexing reverse and feed control ................................................................ 176
Jam detection ................................................................................................................................... 177
Optional input trays .......................................................................................................................... 179
Paper-feeder pickup and feed operation ......................................................................... 182
6 Removal and replacement
Removal and replacement strategy .................................................................................................. 186
Introduction ...................................................................................................................... 186
Required tools .................................................................................................................. 187
Types of screws ............................................................................................................... 187
Service approach ............................................................................................................. 188
ENWW vii
Before performing service ................................................................................................ 188
After performing service ................................................................................................... 188
Parts removal sequences ................................................................................................ 189
User-replaceable parts ..................................................................................................................... 190
Fuser ................................................................................................................................ 191
Transfer roller .................................................................................................................. 194
Intermediate-transfer belt (ITB) ........................................................................................ 196
Tray-1 pickup and separation rollers ............................................................................... 199
Tray-2, -3, -4, and -5 pickup rollers ................................................................................. 201
Formatter ......................................................................................................................... 203
1 x 500-sheet input tray installation ................................................................................. 206
3 x 500-sheet input tray installation ................................................................................. 207
Tray 2 ............................................................................................................................... 208
Trays 3, 4, and 5 .............................................................................................................. 208
Removal sequence 1 ........................................................................................................................ 209
Secondary transfer unit .................................................................................................... 210
Multipurpose drive unit ..................................................................................................... 215
Multipurpose-tray guide (Tray 1) unit ............................................................................... 219
Cassette (Tray-2) pickup unit ........................................................................................... 220
Removal sequence 2 ........................................................................................................................ 221
Rear-left cover ................................................................................................................. 222
Rear-right cover ............................................................................................................... 223
Rear cover ....................................................................................................................... 224
Low-voltage power supply unit ........................................................................................ 225
High-voltage power supply PCA (A) ................................................................................ 226
Lifter drive unit ................................................................................................................. 228
Removal sequence 2A ..................................................................................................... 230
Fuser motor ..................................................................................................... 230
Removal sequence 2B ..................................................................................................... 231
Intermediate-transfer belt (ITB) motor ............................................................. 231
Removal sequence 2C .................................................................................................... 232
Face-down output bin ...................................................................................... 232
Left cover ........................................................................................................ 233
Laser/scanner-fan duct ................................................................................... 234
Removal sequence 2D .................................................................................................... 236
Print-cartridge driver PCA ............................................................................... 236
Removal sequence 3 ........................................................................................................................ 238
Rear-left cover ................................................................................................................. 239
Face-down output bin ...................................................................................................... 240
Left cover ......................................................................................................................... 241
High-voltage power supply PCA (B) ................................................................................ 242
Formatter case ................................................................................................................. 244
DC controller PCA ........................................................................................................... 246
Removal sequence 3A ..................................................................................................... 248
viii ENWW
Environmental sensor ..................................................................................... 248
Removal sequence 4 ........................................................................................................................ 249
Rear-left cover ................................................................................................................. 250
Rear-right cover ............................................................................................................... 251
Rear cover ....................................................................................................................... 252
Face-down output bin ...................................................................................................... 253
Left cover ......................................................................................................................... 254
Print-cartridge driver PCA ................................................................................................ 255
Image-drum motor ........................................................................................................... 257
Removal sequence 4A ..................................................................................................... 259
Fuser fan ......................................................................................................... 259
Removal sequence 4B ..................................................................................................... 260
Print-cartridge feed motor (black) .................................................................... 260
Print-cartridge feed motor (yellow, magenta, and cyan) ................................. 261
Removal sequence 4C .................................................................................................... 262
Cartridge fan unit ............................................................................................. 262
Laser/scanner fan unit ..................................................................................... 263
Removal sequence 4D .................................................................................................... 264
Fuser power-supply unit .................................................................................. 264
Primary-transfer-roller disengagement motor ................................................. 265
Removal sequence 4 Sub-1 ............................................................................................................. 266
Print-cartridge drive unit (yellow and magenta) ............................................................... 267
Print-cartridge drive unit (cyan and black) ....................................................................... 272
Print-cartridge interface PCA (cyan and black) ................................................................ 273
Main drive unit ................................................................................................................. 274
Removal sequence 4 Sub-1A .......................................................................................... 276
Print-cartridge interface PCA (yellow and magenta) ....................................... 276
Removal sequence 4 Sub-1B .......................................................................................... 277
Cartridge-fan duct ........................................................................................... 277
Removal sequence 5 ........................................................................................................................ 278
Rear-left cover ................................................................................................................. 279
Face-down output bin ...................................................................................................... 280
Rear-upper cover ............................................................................................................. 281
Control panel ................................................................................................................... 282
Front-upper cover ............................................................................................................ 284
Right-upper cover ............................................................................................................ 285
Duplex switchback tray .................................................................................................... 286
Reverse cover .................................................................................................................. 287
VOC fan ........................................................................................................................... 289
Duplexing reverse unit ..................................................................................................... 290
Face-down delivery unit ................................................................................................... 291
Face-down cover ............................................................................................................. 293
Removal sequence 5A ..................................................................................................... 294
Scanner cover ................................................................................................. 294
ENWW ix
Laser/scanner assembly (yellow and magenta) .............................................. 295
Laser/scanner assembly (cyan and black) ...................................................... 297
Removal sequence 5B ..................................................................................................... 299
Front door ........................................................................................................ 299
Front-inner cover ............................................................................................. 300
Removal sequence 5C .................................................................................................... 301
Front-door assembly ....................................................................................... 301
Removal sequence 5D .................................................................................................... 302
Color-misregistration and image-density sensor unit ...................................... 302
Removal sequence 5E ..................................................................................................... 304
Pressure-release sensor unit .......................................................................... 304
Removal sequence 6 ........................................................................................................................ 305
Rear-left cover ................................................................................................................. 306
Rear-right cover ............................................................................................................... 307
Right-upper cover ............................................................................................................ 307
Right-door assembly ........................................................................................................ 308
Duplexing feed unit .......................................................................................................... 310
Multipurpose-tray (Tray-1) pickup unit ............................................................................. 312
Removal sequence 7 ........................................................................................................................ 315
Thermopile unit ................................................................................................................ 316
Front-lower cover ............................................................................................................. 317
ITB duct ........................................................................................................................... 318
Optional input trays .......................................................................................................................... 319
1 x 500-sheet input tray ................................................................................................... 319
Right door ........................................................................................................ 319
Lower-rear cover ............................................................................................. 321
Front-right cover .............................................................................................. 322
Right cover ...................................................................................................... 323
Front-upper cover ............................................................................................ 324
Lower-left cover ............................................................................................... 325
Front-lower door .............................................................................................. 326
Box .................................................................................................................. 327
Pickup unit ....................................................................................................... 328
Input tray is not attached ................................................................ 328
Input tray is attached ...................................................................... 329
Auto-close unit ................................................................................................ 331
Pickup motor ................................................................................................... 332
Paper-feeder driver PCA ................................................................................. 333
3 x 500-sheet input tray ................................................................................................... 334
Right door ........................................................................................................ 334
Lower-rear cover ............................................................................................. 334
Front-right cover .............................................................................................. 334
Right cover ...................................................................................................... 334
Front-upper cover ............................................................................................ 334
x ENWW
Left cover ........................................................................................................ 334
Pickup unit (middle cassette) .......................................................................... 335
Pickup unit (lower cassette) ............................................................................ 336
Pickup unit (upper cassette) ............................................................................ 336
Input tray is not attached ................................................................ 336
Input tray is attached ...................................................................... 337
Auto-close unit ................................................................................................ 339
Pickup motor ................................................................................................... 339
Paper-feeder driver PCA ................................................................................. 339
7 Solve problems
Troubleshooting process .................................................................................................................. 342
Determine the problem source ........................................................................................ 342
Pre-troubleshooting checklist .......................................................................... 342
Troubleshooting checklist ................................................................................ 343
Troubleshooting flowchart ............................................................................... 344
Power subsystem ............................................................................................................ 345
Power-on checks ............................................................................................. 345
Power-on troubleshooting overview ............................................... 345
Tools for troubleshooting .................................................................................................................. 347
Internal print-quality test pages ........................................................................................ 347
Diagnostics page ............................................................................................. 347
Configuration pages ........................................................................................ 348
Configuration page ......................................................................... 348
HP embedded Jetdirect page ......................................................... 350
Embedded protocol page ............................................................... 351
Finding important information on the configuration pages .............. 352
Solve performance problems ........................................................................................................... 353
Solve connectivity problems ............................................................................................................. 354
Solve direct-connect problems ........................................................................................ 354
Solve network connectivity problems ............................................................................... 354
Solve network printing problems ..................................................................... 354
Verify communication over the network .......................................................... 355
Control-panel message types ........................................................................................................... 356
Control-panel messages .................................................................................................................. 357
Event log messages ......................................................................................................................... 422
Print an event log ............................................................................................................. 422
Show an event log ........................................................................................................... 422
Sample event log ............................................................................................................. 423
Clear the event log ........................................................................................................... 423
Event log message .......................................................................................................... 424
Paper-handling problems ................................................................................................................. 428
Jams ................................................................................................................................ 428
ENWW xi
Common causes of jams ................................................................................. 428
Jam locations .................................................................................................. 429
Clear jams ....................................................................................................... 429
Jam sensors ................................................................................... 430
AREA 1: Jams in the output bin ...................................................... 431
AREA 2 and 3: Jams in the fuser and transfer area ....................... 433
AREA 4: Jams in the duplex area ................................................... 440
AREA 5: Jams in Tray 2 and the internal paper path ..................... 445
AREA 6: Clear jams in Tray 1 ......................................................... 449
Clear jams when printing banners .................................................. 452
AREA 7: Jams in optional Trays 3, 4, and 5 ................................... 455
AREA 8: Jams in the optional finishing devices ............................. 460
Clear staple jams ............................................................................ 466
Jam recovery ................................................................................................... 470
Product feeds multiple sheets .......................................................................................... 471
Product pulls from incorrect tray ...................................................................................... 471
Product feeds incorrect page size ................................................................................... 471
Paper does not feed automatically .................................................................................. 472
Paper does not feed from Tray 2, 3, 4, or 5 ..................................................................... 472
Transparencies or glossy paper will not feed .................................................................. 473
Envelopes jam or will not feed in the product .................................................................. 473
Output is curled or wrinkled ............................................................................................. 474
Product will not duplex or duplexes incorrectly ................................................................ 474
Solve image-quality problems .......................................................................................................... 476
Example print quality problems ........................................................................................ 476
Repetitive defects ruler .................................................................................................... 476
Overhead transparency defects ....................................................................................... 478
Print quality problems associated with the environment .................................................. 478
Print quality problems associated with jams .................................................................... 478
Optimize and improve image quality ................................................................................ 478
Use supported paper ....................................................................................... 479
Calibrate the product ....................................................................................... 479
Specify the correct paper type ........................................................................ 479
Clean the fuser ................................................................................................ 480
Respond to control panel error messages ...................................................... 481
Clean the registration second transfer assembly ........................... 482
Use manual print modes ................................................................................. 484
Print-quality-troubleshooting pages ................................................................. 485
Image-quality issues ........................................................................................................ 487
Interface troubleshooting .................................................................................................................. 493
Communication checks .................................................................................................... 493
EIO troubleshooting ......................................................................................................... 493
Engine diagnostics ........................................................................................................................... 494
LED diagnostics ............................................................................................................... 494
xii ENWW
Understand lights on the formatter .................................................................. 494
HP Jetdirect LEDs .......................................................................... 494
Heartbeat LED ................................................................................ 495
Engine-test button ............................................................................................................ 495
Diagnostics menu ............................................................................................................ 496
Diagnostics mode ............................................................................................................ 496
Diagnostics that put the engine into the special diagnostics mode ................................. 497
Diagnostic tests ............................................................................................................... 497
Disable cartridge check ................................................................................................... 498
Paper-path sensors test ................................................................................................... 499
Paper-path test ................................................................................................................ 501
Manual sensor test (special-mode test) ........................................................................... 501
Manual sensor test 2 (special-mode test) ........................................................................ 502
Component tests .............................................................................................................. 503
Component test (special-mode test) ............................................................... 503
Print/stop test ................................................................................................................... 507
Color-band test ................................................................................................................ 507
Service mode functions .................................................................................................................... 508
Service menu ................................................................................................................... 508
Product resets .................................................................................................................. 509
Restore factory-set defaults ............................................................................ 509
Hard disk initialization ..................................................................................... 510
NVRAM initialization ........................................................................................ 510
Diagrams .......................................................................................................................................... 511
Connectors ...................................................................................................................... 511
DC controller PCA ........................................................................................... 511
PCAs ............................................................................................................... 511
Product base ................................................................................................... 514
1 x 500-sheet input tray ................................................................................... 517
3 x 500-sheet input tray ................................................................................... 517
IPTU ................................................................................................................ 518
Sensors ............................................................................................................................ 518
Sensors ........................................................................................................... 518
Product base ................................................................................................... 520
1 x 500-sheet input tray ................................................................................... 522
3 x 500-sheet input tray ................................................................................... 523
IPTU ................................................................................................................ 524
Fans ................................................................................................................................. 525
Fans ................................................................................................................ 525
Product base ................................................................................................... 526
Motors .............................................................................................................................. 526
Motors ............................................................................................................. 526
Product base ................................................................................................... 528
1 x 500-sheet input tray ................................................................................... 529
ENWW xiii
3 x 500-sheet input tray ................................................................................... 530
IPTU ................................................................................................................ 531
Solenoids ......................................................................................................................... 531
Solenoids ........................................................................................................ 531
Product base ................................................................................................... 532
1 x 500-sheet input tray ................................................................................... 532
3 x 500-sheet input tray ................................................................................... 533
Switches .......................................................................................................................... 534
Switches .......................................................................................................... 534
Product base ................................................................................................... 534
1 x 500-sheet input tray ................................................................................... 535
3 x 500-sheet input tray ................................................................................... 535
Block diagrams ................................................................................................................ 537
Main assemblies ............................................................................................. 537
Main parts ....................................................................................................... 540
PCAs ............................................................................................................... 541
1 x 500-sheet input tray ................................................................................... 542
3 x 500-sheet input tray ................................................................................... 543
Intermediate paper-transfer unit (IPTU) .......................................................... 544
General timing chart ........................................................................................................ 545
General circuit diagrams .................................................................................................. 545
Signals .............................................................................................................................................. 550
8 Output accessories and intermediate paper-transfer unit (IPTU)
Theory of operation .......................................................................................................................... 580
Intermediate paper-transfer unit (IPTU) ........................................................................... 580
Basic operation ............................................................................................... 580
Feed operation ................................................................................................ 582
Jam detection .................................................................................................. 582
3-bin stapler/stacker ........................................................................................................ 583
Basic operation ............................................................................................... 583
Electrical circuitry ............................................................................ 584
Feed drive system ........................................................................................... 584
Construction of the control system ................................................. 585
Paper delivery path (stapler/stacker and booklet maker) ............... 587
Intermediate-process output-bin assembly (stapler/stacker and booklet
maker) ............................................................................................................. 591
Stack job offset ............................................................................... 591
Process output bin paper-stacking operation .................................................. 593
Offset operation ............................................................................................... 593
Stack trailing-edge assist operation ................................................................ 594
Stack delivery operation .................................................................................. 594
Staple operation (stapler/stacker and booklet maker) ..................................... 595
Staple unit ....................................................................................... 598
xiv ENWW
Shift the staple unit .......................................................................................... 599
Stack operation (stapler/stacker and booklet maker) ...................................... 601
Output bin operation ....................................................................... 601
Shutter operation ............................................................................ 603
Jam detection .................................................................................................. 604
Power supply ................................................................................................... 605
Power-supply route ......................................................................... 605
Protection function .......................................................................... 605
HP Booklet Maker/Finisher accessory ............................................................................. 606
Basic operation ............................................................................................... 606
Basic operation of the stacker unit ................................................. 606
Electrical circuitry of the stacker unit .............................................. 606
Basic operation of the booklet maker unit ...................................... 607
Electrical circuitry for the booklet maker unit .................................. 608
Feed drive system .......................................................................... 608
Paper-delivery path (booklet maker only) ....................................... 613
Basic operation for the booklet maker ............................................................. 614
Control of the inlet flappers ............................................................................. 618
Control of paper movement ............................................................................. 621
Alignment of paper .......................................................................................... 623
Control the phase of the crescent roller .......................................................... 625
Overview of folding .......................................................................................... 627
Control of stack movement ............................................................................. 628
Fold the stack .................................................................................................. 628
Double folding a stack ..................................................................................... 631
Intermediate-process-tray assembly ............................................................... 632
Staple operation .............................................................................................. 633
Stapler unit ..................................................................................... 633
Stapling operation ........................................................................... 634
Stitcher (stapler) unit ...................................................................... 634
Stack operation ............................................................................................... 635
Jam detection .................................................................................................. 635
Detect jams in the stacker unit ....................................................... 636
Detect jams in the booklet maker unit ............................................ 636
Power supply ................................................................................................... 637
Power-supply route for the stacker unit .......................................... 637
Protective function for the stacker unit ........................................... 638
Power-supply route for the booklet maker unit ............................... 638
Protective function for the booklet maker unit ................................ 638
Specifications ................................................................................................................................... 639
Accessory specifications .................................................................................................. 639
Stapler/stacker output-bin capacities ............................................................................... 644
Booklet-maker output-bin capacities ................................................................................ 645
Removal and replacement ............................................................................................................... 646
ENWW xv
Intermediate paper-transfer unit (IPTU) ........................................................................... 646
IPTU ................................................................................................................ 646
Reverse guide ................................................................................................. 648
Rear cover ....................................................................................................... 649
Upper-guide assembly .................................................................................... 652
Damper unit ..................................................................................................... 653
Right-belt drive unit ......................................................................................... 654
Left-belt drive unit ............................................................................................ 657
Finisher-lock assembly .................................................................................... 659
IPTU paper-feed motor 1 ................................................................................ 661
IPTU paper-feed motor 2 ................................................................................ 662
IPTU driver PCA .............................................................................................. 663
Booklet maker and stapler/stacker .................................................................................. 664
Identify the booklet maker and stapler/stacker ............................................... 664
Remove the booklet maker and stapler/stacker from the printer .................... 665
External covers ............................................................................................... 668
Entrance lower-guide assembly ..................................................... 668
Front door ....................................................................................... 669
Rear cover ...................................................................................... 670
Front-foot cover .............................................................................. 671
Rear-foot cover ............................................................................... 671
Front inside-upper cover ................................................................. 672
Front inside-lower cover (booklet maker only) ................................ 673
Left-upper cover ............................................................................. 674
Top door ......................................................................................... 676
Grate-shaped upper guide .............................................................. 678
Move output bins 1 and 2 ............................................................... 679
Grate-shaped lower guide .............................................................. 681
PCA cover ...................................................................................... 682
Drive system ................................................................................................... 683
Stapler ............................................................................................ 683
Stapler assembly ............................................................................ 685
Swing unit ....................................................................................... 688
Upper crossmember unit ................................................................ 692
Saddle unit (booklet maker only) .................................................... 695
Saddle-stapler assembly (booklet maker only) ............................... 699
Positioning plate unit (inner side-plate assembly) (booklet maker
only) ................................................................................................ 700
Document feed system ................................................................................... 703
Operation-tray assembly ................................................................ 703
Output-bin 1 .................................................................................... 708
Output-bin 2 .................................................................................... 710
Upper output bin (stapler-stacker only) .......................................... 712
Buffer rollers ................................................................................... 713
xvi ENWW
Booklet-delivery output bin (booklet maker only) ............................ 714
Booklet-delivery output bin unit (booklet maker only) ..................... 715
Return roller unit ............................................................................. 716
Pressure roller unit ......................................................................... 718
Entrance upper guide unit .............................................................. 723
Upper-delivery guide (booklet maker only) ..................................... 725
Inlet feed unit (stapler-stacker only) ............................................... 726
Inlet feed unit (booklet maker only) ................................................ 729
Paper-folding roller (booklet maker only) ........................................ 732
Electrical system ............................................................................................. 737
Stacker controller PCA ................................................................... 737
Saddle-stitcher controller PCA (booklet maker only) ...................... 738
Solve problems ................................................................................................................................. 739
Intermediate paper-transfer unit (IPTU) ........................................................................... 739
......................................................................................................................... 739
Stapler/stacker and booklet maker .................................................................................. 739
Individual component diagnostics ................................................................... 739
Manual sensor test ......................................................................... 739
Component test .............................................................................. 740
LED diagnostics .............................................................................. 741
Diagrams ......................................................................................................... 743
Cross sections ................................................................................ 743
Sensors ......................................................................................... 746
Microswitches ................................................................................. 750
Solenoids ........................................................................................ 752
Motors ............................................................................................. 754
Clutches .......................................................................................... 756
PCA ................................................................................................ 757
Variable resistors, LED, and check pins ........................................ 760
Circuit diagrams .............................................................................. 763
Adjustments ................................................................................................... 768
Adjust the alignment position .......................................................... 768
Adjust the staple position ................................................................ 768
Adjust the folding position to the stitch position (Booklet maker
only) ................................................................................................ 770
Adjust the stitcher unit .................................................................... 773
9 Parts and diagrams
Order parts, accessories, and supplies ............................................................................................ 778
Order directly from HP ..................................................................................................... 778
Order directly through the software ................................................................................. 778
Customer self-repair parts ................................................................................................................ 780
Customer self-repair parts ............................................................................................... 780
Service documentation .................................................................................................... 781
ENWW xvii
Part numbers ................................................................................................................... 781
Accessories ..................................................................................................... 781
Print cartridges ................................................................................................ 782
Image drums ................................................................................................... 782
Maintenance kits ............................................................................................. 782
Memory ........................................................................................................... 782
Cables and interfaces ..................................................................................... 783
Printer ............................................................................................................................................... 784
Printer unit ....................................................................................................................... 784
Printer parts ..................................................................................................................... 785
Input accessories ............................................................................................................................. 832
Input trays ........................................................................................................................ 832
Output accessories ........................................................................................................................... 850
Intermediate paper-transfer unit (IPTU) ........................................................................... 850
Stapler/stacker and booklet-maker .................................................................................. 858
Alphabetical parts list ....................................................................................................................... 926
Numerical parts list ........................................................................................................................... 952
Appendix A Service and support
Hewlett-Packard limited warranty statement .................................................................................... 979
Print cartridge and image drum limited warranty statement ............................................................. 981
Color LaserJet Fuser Kit, Transfer Kit, and Roller Kit Limited Warranty Statement ......................... 982
Customer self repair warranty service .............................................................................................. 983
Customer support ............................................................................................................................. 984
Availability of support and service .................................................................................................... 985
HP maintenance agreements ........................................................................................................... 985
On-site service agreements ............................................................................................. 985
Priority onsite service ....................................................................................................... 985
Next-day onsite service ................................................................................................... 985
Weekly (volume) on-site service ...................................................................................... 985
Appendix B Product specifications
Physical specifications ..................................................................................................................... 988
Electrical specifications .................................................................................................................... 989
Acoustic specifications ..................................................................................................................... 990
Environmental specifications ............................................................................................................ 991
Appendix C Regulatory information
FCC regulations ............................................................................................................................... 994
Environmental product stewardship program ................................................................................... 995
Protecting the environment .............................................................................................. 995
Ozone production ............................................................................................................ 995
Power consumption ......................................................................................................... 995
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